Fudan University developed a highly efficient UV LED light curing system

Only one-fifth of the original energy consumption, will be able to achieve half the speed of optical fiber production - Fudan University, Institute of Electric Light by Deputy Director, School of Information Science and Engineering Zhang Shan-side and its team developed optical fiber drawing tower with high efficiency UV LED light curing system to complete a technical breakthrough in innovation. The UV LED curing system will debut at the 18th China International Industry Fair. Most of the light-curing ink by the system of irradiation, a few seconds will be able to cure. Such innovative technology of high power density and low energy consumption will make the manufacturing of the optical fiber industry realize a leap forward.

Exceeding the traditional half of the radiation irradiance achieved by one-fifth of the energy consumption

UV LED curing system is the most prominent advantage of low energy consumption. Compared with the traditional microwave medium pressure mercury lamp easily over 6000 watts of high energy consumption, the line light source composed of UV LED consumes only 1200 watts, saving 80% energy consumption.

Microwave medium-pressure mercury lamp is used in the past, usually used in optical fiber drawing tower curing device. In the process of making optical fibers, when the optical fiber is drawn into filaments, it needs to be coated with a protective ink material and cured. Generally speaking, the optical fiber is changed from a liquid state to a solid state. Printing, automotive, electronics, furniture and other industries, production, ultimately, this link. UV curing is the most common fast curing process, the UV-sensitive coating can be cured by the corresponding light source.

However, there are many disadvantages of the microwave light-pressure mercury lamp, which not only consumes too much energy, but also generates large amounts of heat at the time of operation of the magnetron in the microwave. The radiation efficiency is also very low. According to the spectrum, medium-pressure mercury lamp emits only about 10% of the UV light useful for curing, visible light 20%, and calorific value 70%. Its curing efficiency is difficult to meet the growing demand for optical fiber industry production, but also with the current advocacy of the concept of economic and environmental incompatible.

Zhang Shan-end team for this purpose using UV LED light source to develop a more efficient UV curing system, in addition to reducing energy consumption, the traditional equipment only 6000 hours of life, the system will extend the service life of 30,000 hours. After more than a year of continuous operation, almost no light failure, the photoelectric parameters remain the factory state. According to the spectrum, the UV LEDs are very concentrated in the 365 to 385 nm band for optical fiber inks and are more curable than medium pressure mercury lamps. Zhang Shan Duan said: "The new UV LED curing system requires only one-fifth the traditional energy consumption, will be able to achieve twice the traditional radiation irradiance, drawing speed increased by half, and work more long-term."

Leading international LED power density in the world

According to reports, this UV LED light curing system can not only completely replace the traditional microwave medium pressure mercury lamp, compared with existing similar products, in many ways to achieve a technological breakthrough and innovation.

The system consists of optical fiber curing furnace, drive power and cooling system is a combination of three parts, fiber curing furnace is the core of technology, which is one of the LED light source is the most critical part of the entire system. Three years ago, at the fair, Zhang Shan-end team developed UV LED curing system debut, when the UV LED light source can achieve 200 watts per square centimeter of power density, has reached the world's leading standards. This year, the UV LED light curing system for optical fiber drawing towers has raised the maximum package power density to 700 watts per square centimeter, which has firmly established itself as the No. 1 technology in the world.

The industry's most common UV LED chip can withstand only 1 ampere per square millimeter current density, specially designed by Zhang Shan-end LED chip will be able to increase the upper limit to 4.5 amps per square millimeter, mainly due to its innovative package technology.

Another highlight of technological innovation is the efficient UV refraction and reflection system. The optical system includes carefully designed lenses and reflectors that converge the UV light from the light source onto the axis of the cylinder to enhance the axial irradiance and reduce optical loss, thereby increasing wire drawing cure speed.

Boost the production of the future is expected to promote more changes in the industry

At present, the system has declared 6 invention patents, and remarkable technical performance has also brought significant economic and social benefits.

With the help of this system, while maintaining the same system input power, the drawing speed of the fiber drawing tower can be increased by nearly 50% to an astonishing speed of 3000 meters per minute. With just two towers, the output of the three towers is now saved, saving both investment and production, while also reducing energy consumption.

Data show that several international optical fiber giant enterprises in the small-scale use of the system, the last three years a total output value of 1.84 billion yuan, new profits of 300 million yuan, and save 402 million kwh, saving 44.3 million conversion Yuan, 0.4 million tons of carbon dioxide emissions. Therefore, this set of fiber drawing tower with UV LED light curing system for the optical fiber manufacturing industry is a major breakthrough, will effectively promote the innovation of light curing equipment. Zhang Shan Duan certain domestic enterprises in three years to achieve the upgrading of optical fiber curing furnace technology. In the future, the technology is also expected to be used in more areas related to light curing, such as printing, flooring, home, flooring and other industries. The technology also boosts the energy-saving margin to 90% for light-curing paints, woods, printing and other types.